ZYKM1628

MIDDLE SPEED AUTOMATIC

PRINT SLOT DIE CUTTING MACHINE

MANUAL BOOK
l. Uses and Features

ll. main technical parameters

Ill. Machine features

|V .Maintenance and lubrication of machine

V. Swinging and installing of machine

Warning :

The oil-way of every part transmission gear should be check when working , chain wheel place must
be replenished with 20-30 # machine oil. Antifriction bearing of bearing part should be overhauled
cleaning every half year and the replenishment of 23 # calcium base lubricating oil. Ink pump and
air compressor should be supplemented with lubricating oil once per month. Gear box oil should be
replaced once per half year. The oil zerk be injected by manual high pressure oil gun one per week.

The manual book is suitable for ZYKM1628 middle speed print slot die cutting machine
| .Uses and Features

ZYKM1628 middle speed print slot die cutting machine is used for box making line

which from board to box, to feed, print and split , cut corner, slot ect. The machine used for multi-
unit connect, adapt opening and closing of track structure, the electric opening and closing air
pressure type car wall lock system, convenient usage and maintenance. The machine adopt
international famous brands, auto back to zero, clean memory ,preset ect the multifunction
control, memory store 999 orders. Printing slotting die-cutting with phase zero, phase to be pre-
adjust and ne adjustment function, make the printing slot die cut phase adjustment time more
short and higher precision. electric parts application keyless connecting ring, eliminating the gap
generated by the traditional connection, keep the longterm precision of printing chromatic.

Feeding system adapt the vacuum adsorption front feeding system, box board will be adsorbed on
the paper feeding wheel, making the board can be send to the device smoothly, and with electric
control skip feeding to match the larger cardboard conveying.

Printing part adopts the watersoluble ink, ink with dual mode of pneumatic diaphragm pump
automatic cycle, it is easy to change ink or wash ink. Equipped with plate fast hanging version
system, make the operation convenient and quick. Slot creasing unit with electric synchronous
adjustment. Four main shaft all with hard chromium electroplating processing and precision
grinding, make knife wheel moves do not vibrate.

The machine with improve printing topping accuracy design, such as the PLC touch screen
control and planetary electric digital 360 degree adjustment, long service life and easy to adjust
accurately;

Transmission gear is made from alloy steel, which are be heated treatment of hardness,
according to the requirements of high precision processing and manufacturing, and adapt the uid
inltration mechanism, long service life, low noise, smooth operation, ensure color topping more
accuracy.

Wallboard is 60 mm thick cast iron material, after annealing heat treatment deformation,
the machine run smoothly, improve the printing accuracy;

All the transmission roller, shaft are fine grinding, hard chromium plating process;

Automatic cycle ink system, easy operation, ink quantity can trace adjustment. Ink
roller department can rise pneumatic and separated, to prevent downtime when the inkdries up,
and convenient to clean ink roller;

Each unit electric moving , pneumatic locking, relax. With alarm, warning light canimprove the safety
of the operation.

The machine with automatic counting device, can control the production quantity correctly.

The function of every unit:

Q Leading edge unit : sending paper

O Print unit: print single or multi colour

O slot unit: creasing, trim blade, slot , cut corner, punching

(match with punching device)

O Die cutting unit: die the carton board used the die module

9 Stacker: stack the paper board

l|.main technical parameters ZYK1628

Speed: 100 pas/min

Economic speed :80pcs/min

Max. paper size :1600X3000

max. printsize :l600X280

rnin.paper size :400X750mm(whole plate print). 320X750mm(slot size)

min slot interval :260><llO><260>< 110

layer of paper board 23,5,7 layers

standard print plate thickness : 7.2mm

slot knives thickness :8mm

motoer : 37KW variable frequency motor

 Motor and electric parts

Name Original Specification Number

feeding paper unit

1, main electric motor Hebei 37KW frequency control 1 set

2, machines start and Taiwan 3.7KW 1/80 gear motor 1 set

stop

3. adjusting of right and left Zhejiang 0.18KW 1/25 CAVEX 2 set

bafe
4. cleaning and vacuum Heibei 2.2 and 7.5KW each one set
draught fan
printing unit
1, radial phase adjustment Zhejiang 0.37 KW 1/30 CAVEX Four color 4 set

2, axial phase adjustment Zhejiang 0.37 KW 1/60 CAVEX Four color 4 set

3, roller idling Taiwan 0.75 KW 1/40 gear motor Four color 4 set

Slot unit
Axial link motor Zhejiang RV63-1.1 KW 1/25 CAVEX 5 set

2, phase adjustment Zhejiang RV40-0.37 KW 1/30 CAVEX 2 set

die cut unit

1. Phase adjustment Zhejiang RV40-0.37 KW 1/30 CAVEX 1 set

2. Axial phase Zhejiang RV40-0.37 KW 1/60 CAVEX 1 set

adjustment hexagonal 16

3. Trimming motor Zhejiang RV40-0.18 KW 1/40 CAVEX 1 set

4. Stripping machine Zhejiang 1.1 KW 1/30 cycloid motor 1 set

stacker
1. Lifting motor hebei 1.5 kw brake gear motor 1 set

2. Driving motor hebei 2.2 kw adjustable speed 1 set

motor
When the board neta, size is moderate, intensity bigger the machine can run in very good
condition. Parameters as follows: 350 < board width < 1200. When the board width is less than
350 mm, the spped should be below 80 pieces per minute, and in accordance with the need to put
rubber in the printing roller to auxiliary feed. When cardboard warping, according to the degree of
warping to reduce speed. When large cardboard warping should make in smooth before using.

Specification table

1. Print unit
Four axis front edge paper sending unit with 11 kw blower fan, suction to help sending
paper, the air volume can be adjust according to the cardboard degree of bend, frequency
conversin air volumen adjustment, make sure to send paper smoothly. ( using method as
show in the leading adge operation instruction )

The air volume is adjustable, sending paper dangling (paper raise) system is controlled by
cylinder. Equipped with dust removal fan and the brush whish can eliminate impurities on the
surface of the cardboard, improve the quality of the printing.

Paper roll designed ahead and rear two-axis structure, ahead paper shaft is pneumatic type
elastic rubber roller which don't destroy the strength of corrugated board, the inner rubber is
soft and outer is hard which are good stretching resistance and wear, prolong service life,
lower feed roller steel embossing plating processing.

2. phase adjustment :

Planetary gear phase variable frequency electric adjustment, the version of roller circumferential
360 degree adjustment, input button electric operation can also touch screen digital adjustment,
accurate and convenient.

Ink circulate adopts pneumatic ink pump, ink stability, simple operation and maintenance.

Ink mesh lter impurities, to protect network roll.

Print plate with hanging scroll version, unilateral lock, make the version of contrapuntal accurate,
convenient, fast. Full version hangs groove, suitable for 10 mm version of the article. When loading
and unloading the print unit, foot switch of electric control and reversing are convenient and
exible.

3. slotting unit

creasing roller

The creasing roller with precreasing gear ,after the board be precrease the board is not easy to
be crush. The up gear With nylon, down gear with 45# cam to make sure the creasing line is
accordance. '

slot roller

Unique two-axis double slot structure, eliminate colliding of ahead and rear blade, and shorten
changing order time , make more quick.
 Slot knives thickness is 8 mm, which from steel material by grinding and heat treatment ,
the knives edge more sharp.

Phase adjustment adopts planetary gear motor phase. PLC computer and dual system
control buttons and can store 999 orders.

Up and down site of Slotting knife, up and down pro-creasing gear , wheel lateral

movement which are matched with the axial synchronous electric adjustment, make the knives
moving more exible and accurate.

4. transmission gear

Gear is made of alloy steel, the thickness of up to 60 mm, high wear resistance, easy
maintenance, etc.

5. The machine body from HT - 250 material , the thickness 60 mm, shock absorption performance
is good, braced by GB channel steel, solid and stable. Set the electric opening and closing.

6. Electrical part features: the domestic and international famous brand electrical control
components, reliable operation, the circuit design is reasonable, easy operation, long service life.
I I |. Machine features

1. feeding unit

(1) (main parts of feeding unit)

Lead edge feeder system ------ feeding is precision and steady

Side bafe system ----- ensuring the position of paperboard

Front bafe system ------ ensuring the position of starting and ending'of paperboard

Feeding roller system feeding the paperboard to the printing unit exactly .

Adjusting space of feeding roller system using for different thickness of paperboard

Cleaning system using to clean the paperboard

Power system offering power of machine

Moving system using for the moving of the machine

Locking system using for the printing unit or other units to lock and connect together

Lubricating system using for lubricating the gear and bearings.

Electric device system using for setting ,adjusting and controlling the parameter of machine.
(2) Adjusting position of paperboard system

A: Paper board position adjustment.

Lateral bafe:Setting principle of Paper feeding unit: Regards the machines mid line as the
midline, divide the area equally. The interval of the two lateral bafes is bigger than the board
length,about l-2mm is better,thus can put the paper board on the working table smotthly.

The bafe can be adjusted by electric. There is left bafe control and right ballfe contron
button on the master panel. And read the graduated scale.

Head baferse the interval adjustment structure to adjust the bafes up and down, run the
paperboard thickness adjusting handle which is at the right of the protactive guard. It is better to
put a board between the head board and feeding paper table. The interval is: board thickness*l.5
to board thickness*l.6mm, make sure not to more than twice as the corrugated board. Read actural
size refer to the dial.

Make sure enough Width between the two bafes. Thus can put the board into machine
somoothly, generally will be the 3/4 of the boardcan read the scaleplate for reference. Setting the
width of bafe and adjustment can be move along the guide shaft by manual.

The gap between head bafe and back bafe settingzadjust the position of back board and
pushing bafe, it is advisable to put 3-4 pieces of cardboard at the same time, so as to reduce the
kick plate resistance of feeding paper, protect the board from damage into paper in printing plate,
the front top in front, the back end to tight the tailgate (lift car side of the paper). It has proved that
the distance tetween head bafe and back bafe is larger than the board width,about 0.5-1 mm.

Four axis leading feeing unit:7.5 KW blower, suction realize automatic feeding, vacuum
adsorption auxiliary feeding device, the device can prevent the shift and make warping cardboard
into the device smoothly. Before feeding platform box bottom is equipped with air conditioner,
according to the cardboard warping, damper opening size, to adjust the air volume and the
adsorptive power, ensure the board at.

B: the paper operation

Paper is equipped with a "normal", "skip feeing paper" two kinds of mode, function is as follows:

"Normal" : machine and cardboard location after adjust good, normal into the board, the knob to
the left.

" skip feeing paper " : 12005cardboard lengthSlSOO, knob to right. The knob in the middle position
for the paper on standby.

Quick wearing parts, in addition to the electrical appliances, rubber roller conveyor, after giving lugs,
brush, paper feed axis on the pressure spring, triangle (main motor), lead feeding refer to attach
document.
2.Print unit

Press print components -- the printability of printing department components

Print plate roller components used to install the print plate

Sending out components for a unit delivery board;

inked components - is used to transfer ink to printing units;

exo ink system-- to provide the ink to glue roller and roller anilox roll place;

lock unit - used to lock and closing the print unit and other units;

lubrication system-- used for lubrication of gears, bearings;

Electric control system used to set machine working parameters, adjust and control

(l)Press print components -- the printability of printing department components , The gap between
the Press print roller and the version roller has very big relations to the print quality, but the gap
size is also has relations to the printing version quality, the shape of the corrugated cardboard and
the surface paper quality. The gap size should be carried on adjustments in the actual printing
production process (printing pressure of 4kg/cm2 is suitable).

For the adjustment of the roller and the version roller parallelism general, the gap between the two
sides should be within 0.05mm.

The gap between press print and roller is adjust by right side handwheel, on the scale degree value.

Print plate roller components -- used to install the print plate, its surface are processed by grinding
and chromium plating.

Hanging version: shaft hanging version, before install the print plate, please check if the
thickness of the plate conform to the standard requirements. loosen lock knob screw which on
control panel, push unit separation button, separate to about 600 m, using a wrench to move the
ratchet wheel, make the scroll loosen, insert plastic plate to roller groove, and aimed at the center
line, with the foot pedal switch, make the print roller rotation in a circle, insert the other side of
plastic plate to groove, using a wrench to move the ratchet wheel making the scroll lock the plastic
print plate.
 roller phase adjustment: the machine with 360 electric phase adjustment and electric
traverse adjustment (adjustment distance :: 10 mm, frequency conversion control, controlled by
PLC touch screen and buttons, which can adjust printing position and revise anytime. The printing
phase xing device adopts the electromagnetic clutch brake mechanism, when the machine or
adjust the phase separation, the brake institutions limit the machine running and keep original gear
xed point position. With back zero, reset, clean version of the memory, and other functions.

(3)Sending out components - for a unit delivery board; its gap size and the parallelism can
inuence chromatography precision directly, method of controlling the gap between up and down
delivery rollers and the parallelism : the gap between up and down delivery rollers is smaller than
0.1-0.2mm. Easy way is to insert the paper board, it is good on the condition that board can be drag
out under little effort , but not leave feeding wheel pressure mark on the board. (the adjustment
diagram shown in figure 1) The numerical size can be adjust by turning the right side hand wheel.

inked components are made up of anilox rubber roller and its adjusting mechanism. The water-
based ink be uniformed by rubber roller (uniform ink roller),then be transferred to guide print plate
by the anilox roller.

Anilox roll and rubber roll gap directly affect the design of color shades, printing ink layer
thickness. The gap is small , the two roller pressure higher, when pressure is too large, because of
the rubber roller with high middle that will cause the middle be wear, then it will easily appear ink
leakage phenomenon in the middle , and because of the pressure is too large, ink roller take little
ink, cause printing pattern color light. When pressure is small, the gap is bigger, the anilox roll with
too much ink, and printing picture color depth and make small picture is fuzzy. The both side gap of
anilox roll generally should be controlled within O.l mm, the numerical size can be adjust by the
right hand wheel, it can be exactly adjust when printing . (its adjusting diagram shown in gure

The parallelism of anilox roll and plate roller directly affect the inking conditions of ends of
the plate in large area printing. The adjustment is done by adjust the rocker screw on both sides of
(anilox roller and glue roller parallelism has been set before delivery). The gap between anilox roller
and the plate roller is adjusted by the eccentric CAM, its gap size is suitable when anilox roller and
the plate roller be light touched, it can be exactly adjust when printing: The print plate inking gap
increasing is by turning ratchet wrench, the digital more big the ink becomes weak, after reach the
maximum gap please turn the ratchet wrench in reverse direction digital gap decrease, inking more
heavy.

Please special attention when the anilox roll and rubber roller compaction, and absence of
ink or other liquid, it not allow two rollers rotation. Before starting the machine, please wash the
rubber roller and roller with water, after clean the dirt, dust and particles then it can be add the ink.

The printer ink system using waterbased ink, the ink can make substrates fast absorption
and quick drying. Ink be send to the anilox roll and rubber roller by ink pump, take the length
direction ow to the side of roller, excess ink ow to the ink fountain, after ink pipe be back to the
ink storage barrels by gravity, continuous cycle. Ink into two roller to ow smoothly between
continuous don't splash is advisable. Before the anilox roll and rubber roll apart, please clean them
by water, do not take ink separately, or it may pollution print plate roller.

Wearing parts list: in addition to the electrical appliances, inking rollers, the ink pump rubber pad,
volume edition axis lter, ink pump , the ratchet wheel and pawl, bearing of anilox and rubber roller,
car wall cylinder, and anilox roll lift cylinder, distributing motor synchronous belt, etc

Slot department:

Pressing the line, the slot, the trimming and slicing the corner can be completed in the department.
'

1) The inserting knife depth adjustment: The slot lower shaft can be adjusted freely, the
adjustment method is the same as that of the gap adjustment of the paper feeding, it
be all right to leave no tracks on the cardboard.(lts adjustment schematic drawing is
chart 11).

2) The adjustment of the depth of the pressing line: The lower shaft of the pressing line
can be adjusted freely, the adjustment method is the same as that of the gap of the
paper feeding. lts suitable when it can press out the indentation on the cardboard
which suitably folds, but it cannot destroy the cardboard. It must be acted according
to the actual situation of the cardboard. (Its adjustment schematic drawing is chart 1-
1).

3) The adjustment of the pressing line and the slot (a straight line): The pressing line
and the slot cutter are adjusted, simultaneously by hand .That is adjust the pressing
line position when adjusting the slotter width .

4) Adjustment of the slot position in the paper feeding direction: This machine uses the
single cutter structure, which means every two groups of slot knives are installed in
the same knife stand, the adjustment of the box high is the distance adjustment of the
two groups of slot knives, when adjusting, first loosen the screw on the slot back knife
in the circumference directional rotation, with the 15# spanner clamp the jacket of the
hexagonal roller, move the hexagonal roller. At the same time the flexible cutter also
moves to the circle direction .Judge the shifting distance according to the mark
position of the knife nose and the ruler.(The fasten tool nose position is O).When it
gets the setting position ,take the spanner down. Tighten up the screw of the
hexagonal roller seat. '
 5) Slotter adjustment on the breath direction position:

Before adjusting, move the knife roller to set the upper blade in the lower knife loosen the axial
direction fastening screw of the upper and lower knife and creasing roller seat. Revolve the adjusting
rack bar of the upper knife seat to the right position of the upper and lower knife seat with the knife
seat adjusting spanner. Tighten the axial direction fastening screw of the knife and creasing roller
seats, start the machine after adjusting the 4 groups of knife seats. First observe the gomphosis
status of the upper and lower knife, then improve the productions when all is OK.

6) The height control of the cutting angle: When the cardboard cannot be cut off, stop
the machine and loosen the screw on the cutting knife stand and adjust with inner
hexagonal head wrench to twist the adjusting screw, the micro adjustment is OK, it
is no use adjusting too much. Its all right to cut off the cardboard when the knives
meet.

Note: before the machine working, check the slot, trimming knife if shifting, conrm the up and
down knife if alignment

Wearing parts list: in addition to the electrical appliances, slotting cut comer trimming knife,
dial the piece, screw, creasing wheel and carved paper cutter, car, cylinder wall, etc.

4. Die cutting part

Component of die cutting roller(lower roller)--it is used in die cutting installation

Component of rubber cushion roller(upper roller)-it is used in die cutting plate installation

Component of clearance adjustment-it is t for different thickness cardboard

Repair component ----- it is used in cushion repair

Component of cardboard feeding rollers ------- it is used in cardboard leading in from printing unit;

Lubrication system ------ it is used in lubricating of gear/bearing.

Electrical control system ------ it is used in set/adjust/control of machine

1, Die cutting roller(lower roller)

1) Diameter of die cutting roller is (1)480mm (it do not including thickness of die
cutter plate)

2) There are many screw on die cutting roller(clearance between screws is

50mm*56.1mm) it t for different size die cutter plates.

3) It fit for die cutter plate height 25.4mmo

4) Pneumatic lifting for rubber cushion roller, it is lifting automaticlly when stop
working, it does not damage the rubber cushion. Lifting of rubber cushion roller is
controlled by threeposition buttons, it does not work when point to middle position;
it falls automaticlly when point to automatic posiotn ,and it need to manual fall the
roller when point to manual position.

2, Rubber cushion roller (upper roller)

1 ) Diameter of rubber cushion roller is (p434.2mm, thickness of rubber cushion is 8 mm (diamter

is (p434.2 mm) , 250mm>< lOpc

2 ) Rubber cushion roller can horizontal moving 58.8mm, it can improve the service life of rubber
cushion .

3 ) It takes differential compensation device, it adjusts the speed autoamticlly,it can insure the same
size for repeat order.

3\ Phase and clearance adjustment structure

Phase and clearance adjustment is same as printing part

4\ Trimming device:

l) Lead screw rotation is driven by worm gear reducer, which drive the repair knife moving in
left/right and trim the rubber cushion .The rubber cushion is in good shape and right position after
trimmed ,it can reduce the die cutting pressure, improve the service life of rubber cushion.

2) Forward trim and backward trim button on control system make the repair knife move to
side ,put the stop button ,it stop repairing.

2 Wearing parts list: cushion, roller cylinder, movement device KR bearing, gear box.

Operation of control part

1. preparations before working:

Turn on the power ,the power light is on.

1 Put the emergency stop button on loose position.

2 Connect the threephase power.

2. Run the machine

3 Push the warning light,remind the worker pay attention.

1 <l> main motor is variable-frequency, start in two steps: put the start button,contactor
actuation and auto-locked,indicator light is on,motor runningspeed up/down button rotating is
controlled by variablefrequency,adsorption fan started.

1 <2>air compressor start2Push the air compressor button ,contactor actuation and auto-
locked,indicator light is on,air pump motor is on.(this button is on the slotter part).

2 <3>stop the machine

3 Push the button of air compressor, its motor stop working.

4 Early warning button control the electrical belt, remind the worker pay
attention.Emergency stop button is cut off the power.

forward rotatingbackward rotating buttons on the back bafe control the rotating of
main motor. working light button controls the working light on and of . dust suction fancontrols
the dust suction fan on and off.

Touch screen: All printing phase adjustment, remember, resetting, zero clearing, count,
order storage and plate lifting function.

Whole machine operation: adjust all cardboard feeding gap, install the printing plate
correctly. To adjust the gap between anilox roller and printing roller, adjust the printing plate phase,
adjust the gap between anilox roller and rubber roller, check the rotating situation of rubber roller,
star the pump and open the ink supply device button and adjust the ink volume. To start the main
motor and run in low speed, put the cardboard for test printing ,if it is ok ,then speed up and begin
to production.

IV. Maintenance and lubrication of machine

 1. Lubrication

1 Add the 2030# oil on the transmission gear before starting, add 23# calcium base
grease on chain wheels. check and wash the bearing located at support part and add 23# calcium
base grease

1 Add lubricated oil on ink distributor motor every month. Replace the lubrication oil within
three month since the day when new machine working. After three month machine running, replace
the lubrication oil when machine worked 2000 hours.

Lubricating the lubricating nipple every three to five days.

2. Maintenance

2 Clear the printing part after working as below: move the ink bucket, and replace the clean
water bucket, automatic clearing the ink system until the water is clean. Stop the ink distributing,
separate the rubber roller and anxiol roller, dry the water.

V.Swinging and installing of machine

3 It should swing individually with crane.

l The machine should be installed on concrete of foundation.

Up gap increase

Down gap decrease

Paper-feeding impression space

Working state of the pump

1. Pull out the knob when working

2. The knob for adjusting the amount of the ink (the amount of ink becomes large
when turning in the clock-wise direction; the amount of ink becomes small
when turning in the anti-clockwise direction)
3. The pipe for absorbing the ink.

the off state for the pump